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 ProSimulator -  SIM Infosystems (Chennai)

       
ProSimulator:
210 MW Thermal Power Plant Simulator, Dlesel Power Plant Simulator, Power Plant Sub-Systems, Process control & Instrumentation Simulator, Basic process Operations, Refining, Gas Processing, Fertilizer, Petrochemicals, Power & Utilities.

 
SIM INFOSYSTEMS Chennai, the World Leader of Process and Power Plant Simulator Systems, offers affordable operator training solutions which can only be provided through high fidelity, dynamic, real-time simulation.
Operators have a vital role in plant operations. However, with increasing reliability of distributed control systems (DCS) and growing use of advanced control, operators have less “hands on” operating time. Their role is becoming less active, more passive – until there is a problem.
Operator Training Simulators have important functions: Train operators on a new process Train new operators Provide understanding of control principles Optimize performance Provide “stress” training without risk Teach basic process principles Maintain and improve expertise.
Operator Training Simulators, OTS, are basically used for training operators in all aspects of plant operation, that is, to handle normal and abnormal operations.
 
Sample Screenshots:
 
       
         
    
    
  
ProSimulator features:
ProSimulator is a complete training simulator package and consists of: Simulator hardware ProSimulator Instructor Software ProSimulator Emulation or Direct Connect Operator Station for various DCS ProSimulator Standard or Custom Process Models for:
- Process control & Instrumentation
- Basic process Operations
- Refining
- Gas Processing
- Fertilizer
- Petrochemicals
- Power & Utilities User Documentation, Software Licenses, training and support

We can provide in our simulator, full function Direct connect interface to various DCS or provide emulation software for various DCS like Yokogawa Centum CS3000 / VP, Honeywell TDC3000 / Experion, Fox I/A and ABB Harmony.
ProSimulator Instructor station enables the instructor to control and direct the training sessions. From the Instructor station, multiple independent training sessions can be invoked by the Instructor and each training  sessions can be assigned to work with one or more operator stations.
 
Typical Setup:  
 

    
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ProSimulator Standard Modules: 

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PS-5000 Power plant Operations Suite

PS-5010 210 MW Thermal Power plant
PS-5011 210 MW Thermal Power plant - Fluidized Bed boiler
PS-5012 140 MW Thermal Power plant
PS-5013 600 MW Thermal Power plant
PS-5020 Gas Turbine Operations
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PS-5016 Diesel Power Plant Operations
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PS-5030 Boiler Operations Suite
PS-5031 Pulveriser Fuel system
PS-5032 Oil Firing System
PS-5033 Flue Gas and Air system
PS-5034 Superheater & Reheater SYSTEM
PS-5035 Boiler Drum
PS-5036 Water Treatment plant
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PS-5040 Turbine Operations Suite
PS-5041 Condensate system
PS-5042 Deaerator system
PS-5043 Condenser vacuum system
PS-5044 Circulating water system
PS-5045 Cooling water system
PS-5046 Gland sealing system
PS-5047 HP LP by-pass system
PS-5048 Turbine steam extraction system
PS-5049 Turbine lube oil system
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PS-5050 Electrical Operations Suite 
PS-5051 Generator cooling water system
PS-5052 Generator System
PS-5053 6.6 KV System
PS-5054 415 V System
PS-5055 220 KV Switchyard
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PS-5060 Balance of Plant (BOP)
PS-5061 Coal Handling Plant
PS-5062 Ash Handling Plant
PS-5063 DM Water plant
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PS-1000 ProSimLab
Control & Instrumentation Suite
PS-1001 On-Off Level Control
PS-1002 On-Off Temperature Control
PS-1003 PI & P Controller
PS-1004 Pressure Controller
PS-1005 Level Controller
PS-1006 Direct and Cascade Control
PS-1007 Split Range Pressure Control
PS-1008 Ratio Control
PS-1009 Feedback and Feed-forward Control
PS-1010 Three Element Boiler Control
PS-1011 Control Valve Characteristics
PS-1012 Characteristics Co-Efficient of Control Valve
PS-1013 Rangeability of Control Valve
PS-1014 Interacting and Non-Interacting Level Systems
PS-1015 Basic Instrumentation Troubleshooting System
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PS-2000 Basic Process Operations Suite
PS-2001 Distillation
PS-2002 Superheated Steam Boiler
PS-2003 Centrifugal Pump
PS-2004 Flash Tank
PS-2005 Heat Exchanger
PS-2006 Natural / Forced draft furnace
PS-2007 CSTR
PS-2008 Fixed bed reactor
PS-2009 Plug flow reactor
PS-2010 Cyclone separator
PS-2011 Crystallizer
PS-2012 Centrifugal Compressor
PS-2013 Reciprocating compressor
PS-2014 Evaporator
PS-2015 Blending
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PS-3000 Refinery Operations Suite
PS-3001 Atmospheric Distillation Unit (CDU)
PS-3002 Vacuum Distillation Unit (VDU)
PS-3003 Fluid Catalytic Cracking Unit (FCCU)
PS-3004 Hydrogen Generation Unit (HGU)
PS-3005 Hydrodeslphurization Unit (HDS)
PS-3006 Catalytic Reforming Unit
PS-3007 Continuous Catalytic Regeneration Unit (CCR)
PS-3008 Hydrocracking Unit (HCU)
PS-3009 Sulphur Recovery Unit (SRU)
PS-3010 Amine Treating Unit (ATU)
PS-3011 Delayed Coker unit (DCU)
PS-3012 Diesel Hydrotreater Unit (DHDT)
PS-3013 Naptha Hydrotreating Unit (NHT)
PS-3014 Isomerization Unit
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PS-4000 Fertilizer Operations Suite
PS-4001 Ammonia plant
PS-4002 Urea Plant
Ps-4003 Sulphuric Acid plant
PS-4004 Phosphoric Acid plant
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PS-6000 Gas Plant Operations Suite
PS-6001 Gas Oil Separation Plant (GOSP)
PS-6002 Degassing Plant
PS-6003 Gas Dehydration unit
PS-6004 Gas Compression Plant
PS-6005 LPG Unit
PS-6006 NGL Recovery Unit
PS-6007 LNG Plant
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PS-7000 Petrochemical Operations Suite
PS-7001 BTX Production
PS-7002 ETHYLENE OXIDE Production
PS-7003 PHTHALIC ANHYDRIDE Production
PS-7004 STYRENE Production
 
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PS0020: ProSimulator Simulator Model Development package:
 
ProSimulator Model Development package is a totally integrated set of simulation software development modules for process plants. It is used by simulation engineers to configure, test, and document dynamic process simulation programs. These programs represent the power plant and are used in the operator training simulator. The package consists of the following sections:
Simulation database Simulation model library Instructor configuration utility Operator station configuration utility Graphic builder Model view / debugger.
 
      
  
Library modules are typically equipment, unit operation and functional modules. Modules that simulate unit operations include: compressors, distillation sections, drivers, heat exchangers, pumps, valves, and vessels. Some modules provide structural functions for the model, such as: source, sink, divider, mixer, and pressure node. Other modules provide instrumentation and logic functionality, for example, control processors, level transmitters and compressor surge controllers.
The model development tool kit requires Microsoft Visual C++ compiler and the same will be provided in the Engineering station.
The development toolkit software shall have the ability to: Build custom property packages Add proprietary reaction kinetic expressions Develop specialized unit operations for other process plants The simulation software shall permit on line view of the internal process model variables, permit models to be created and modified off line, and permit simultaneous development of two or more models.
 
The Simulation Model Development Tool is the core of the model development environment. The user trained in simulation model development environment will be in a position to modify the model using this proprietary tool.
 
Standard library routines available for the following items. Centrifugal Pumps Fans Heat Exchangers Compressors Distillation Evaporators Ejector Heater Multi component Flash Cyclone separators Filters Mixed properties Pressure flow network PID Controllers Indicators Switches Manual Loading Stations Valves Safety Valves Thermodynamics Properties Steam Table Logic & Interlocks
The simulation model development environment has all the relevant simulation algorithms like the following. Euler Integration First order Lag Matrix Solver Scale Pulse Zero Limiter Boolean Power Random Number Generator
Return Max Value Return Min Value Limit between Max and Min Values.
 
Instructor Station Configuration:
This tool is to configure the Instructor Station features like Initial conditions, failure, disturbance etc. This tool is template based and easy to use.
 
Operator Station Configuration:
This tool is to configure the Operator Station features like tag details, groupings, etc. This tool is template based and very easy to use. Also one can import/export data from/to XL file.
 
Graphics Development Tool:

Graphics Development Tool kit enable the user to draw graphics for the simulation model. ProSimulator uses Glg Toolkit of Generic Logic Inc for Graphics development. We use a cross-platform RAD tool for developing dynamic data driven graphics and visual components. The Toolkit includes an interactive Graphics Builder for creating 2D and 3D dynamic graphic displays.
 
Simulation Library:
Compressors:

o Based on regressed compressor curves (including surge calculations)
o Discharge temperature based on polytropic coefficients single-stage/Multiple-stage
Drives
- Electrical drive (constant speed) and Steam drive
Gas fired Heaters with Stoichiometric Combustion
Heat Exchangers
o Two phase adiabatic flash on process streams
o Process-to-process
o Process-to-utility
o Thermosiphon or kettle reboilers
o Partial, total or subcooled condensers
o Correction factors for multiple passes
Pumps - Simple (fixed discharge pressure) and Rigorous
Sinks - Boundary exit points to simulate downstream pressures
Sources - Boundary entry point for the flow sheet
Isothermal Flash sets the product stream phase split
o Trays (single Tray, Trayed Sections)
o Absorption
o Stripping
o Narrow boiling
o Wide boiling
o Multiple feeds, vapor and liquid side draws
o Pressure drop and weeping calculations
o Stream component and overall K-value adjustments
Valves
o Linear
o Equal Percentage
o Modified equal percentage
o Quick acting
o Fail open/close/none
Vessels
o Handles Liquid-full systems and vapor underflow
o Vertical/horizontal
o VLE/No VLE
o Decant water
Distillation, Light end Distillation, Absorber, stripper, Fractionator
Reactors: CSTR, PFR, FBR, Fluidized bed Reactor
Vessels and Separators: Vessels are modeled with all appropriate equipment characteristics. Each vessel has a cross-sectional area and total volume. Vapor phase pressure is determined by vapor inventory, temperature and available vapor volume. All vessels will be modeled with the same size as the actual equipment. The phase equilibrium of the separator is normally determined by the upstream processing equipment and then accumulated and then accumulated in the separator. In most cases, entrainment rates are not simulated unless specified by instructor malfunction.
Heat Exchangers: The dynamic response of the heat exchanger will be provided by considering the heat transfer rate as a function of the operating conditions. Air coolers and shell / tube heat exchangers are simulated as single units.
Hot and cold side temperatures in heat exchangers are normally dynamically calculated. Stream specific heats, heat of vaporization / condensation (where applicable) and overall heat transfer are used in the temperature calculations. Heat transfer is a function of tube and shell side flows, area for heat exchange and exchanger driving forces using AMTD and LMTD. Dynamic conditions in the plant may lead to temperature differences being negative or zero. Under such circumstances, mathematical solutions will not be possible with LMTD. Use of AMTD does not present any mathematical problems.
 
Mass inventories are used to determine the applicable system time constants.
Some exchangers will be simplified (ie. air cooling, etc.) using the assumption of constant temperature on one side to calculate the outlet temperature of the important process fluid.
 
Ambient air temperature will be provided as a instructor variable (inputs) These parameters will affect heat exchanger performance.
 
Heat exchanger fouling, by the instructor, is incorporated as an external parameter to the heat exchanger module and will influence the overall heat transfer.
Motors: The proposed simulation and scope of simulation will not include the power supply systems. Therefore, the simulation of motors will be simplified, but include a reasonable approximation of the motor run-up / run-down time. If speed is controlled, the speed controller will properly alter the motor speed to the desired setpoint.
 
Filters: In general, filters are modeled in a simplified manner. The filter efficiency will assumed to be ideal. Plugging will be an instructor variable and the appropriate loss of flow will be determined by a loss of system conductance.

Thermodynamics Options:
The thermo pack has the following major components: Pure component basic property database Pure component property estimation Petroleum fraction property prediction from MW / BP/ Sp. Gravity Mix property calculation
 
The following properties are available:
Molecular weight Density Watson K Carbon number Enthalpy Specific heat Thermal conductivity Viscosity Surface Tension Pour point Flash point Critical temperature, pressure Accentric factor Compressibility factor FBP, IBP Vapor pressure Weathering Equilibrium K Value ASTM/TBP/EFV conversion Saturated properties of Steam, Water Solubility % Recovery @366 Deg C
 
ProSimulator can also be integrated with any other 3rd party MVPC controllers. This integration can be done either using OPC/OLE compliance.
 
User Manual
The Model Development Package User Manual provides complete information to the simulation engineer about the organization of the software package, description of all Algorithms in the Libraries, procedures and tasks required for the dynamic simulation project, and several examples. Each of the above nine topics is a chapter in the manual.  
 
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Benefits of ProSimulator:

- Improve understanding of plant theory and concepts.
- Increase knowledge of plant systems, their function and interaction with other systems.
- Steady state operations
- Enhance understanding of plant control theory and operation.
- Gain operating experience, confidence, and accuracy in normal and abnormal plant operations.
- Provide practice following specific operating procedures.
- Demonstrate recovery from various upsets and malfunctions.
- Efficient startup and shutdown

Train your student operator to run unit operations thru refinery, gas processing, chemical and utility process units. Choose from the Library of Standard Models or use Customized Models which more closely resemble your plant equipment / controls. Install the high-fidelity ProSimulator Operator Training Simulator.

Key Customers Educational:
1 NIT Silchar,ASSAM.
2 JIS College of Engineering,West Bengal.
3 Madhav Institute of Technology & Science, Gwalior.
4 Adiparasakthi Engineering College.
5 Aligarh Muslim University,Aligarh.
6 Anna University, Chennai.
7 Annamalai University, Chidambaram.
8 Banasthali University, Rajastan.
9 Bandalkand Institute of Engineering & Technology, Jhansi.
10 Bapuji Institute of Engineering & Technology, Davangere.
11 BMS College of Engineering, Bangalore.
12 Calcutta University,Kolkata.
13 Dayananda Sagar College of Engineering, Bangalore.
14 Deenbandhu Chhotu Ram University of Science and Technology.
15 Government Engineering College, Gandhinagar.
16 Government Engineering College, Ujjain.
17 Government Polytechnic, Gandhinagar.
18 HBTI, Kanpur.
19 Jadavpur University, Kolkata.
20 Maliviya National Institute of Technology, Jaipur.
21 Manipal Institute of Technology, Manipal.
22 National Institute of Technology, Warangal.
23 Rural Engneering College, Hulkoti.
24 SDM College of Engineering, Karnataka.
25 Sri Venkateswara College of Engineering.
26 Vivekananda Institute of Technology, Bangalore.
 
Key Customers Corporate:
Refineries:
• HPCL Mittal Energy Ltd (HMEL) thru’ Yokogawa India
• Indian Oil Corporation Ltd, Guwahati refinery, India.
• Petro Rabigh, Saudi Arabia thru’ Omega Simulation
• Oman Refinery Company, Oman
• Petron Batan, Philippines thru Yokogawa Asia Pte
• Nagarjuna Oil Corporation Limited, Chennai, India
• Chennai Petroleum Corporation thru’ Yokogawa India
Gas / Oil Separation
• ISG, Algeria thru’ Omega Simulation Co.
• Petroleum Development Oman (PDO), Oman
• Kuwait Oil Corporation (KOC), Kuwait
• Hassi Messaoud LPG, Algeria thru’ Omega
• Khurais, K.S.A thru’ Omega Simulation Co.
• IOGR, India thru’ Omega Simulation Co.
• Qatar Petroleum, Doha, KSA
• PTTEP, Thailand thru’ Yokogawa Asia Pte Ltd
• PTT, Thailand thru’ Yokogawa Asia Pte Ltd
• TTMS, Thailand thru’ Yokogawa Asia Pte Ltd
Power & Utilities
• EÜAŞ Kumburgaz Eğitim Merkezi Müdürlüğü., Turkey
• ESSAR Power plant thru’ ABB, Bangalore
• Volta River Authority, Ghana
• TATA Power Company, Mumbai, India
• OEG India, Chennai
• IPMA, Bhopal, India
LNG Storage Terminal
• Hazira LNG Terminal Ltd (HLPL) thru’ Yokogawa India
• GNL Quintero, Chile LNG Terminal, thru’ Omega
• Adriatic LNG Terminal, Italy thru’ Omega
• South Hook LNG Terminal, Italy thru’ Omega
Petrochemicals / Chemicals
• NIGC Phase 8 (Saudi Arabia) thru’ Omega Simulation
• FPCC Taiwan thru’ Omega Simulation Co.
• Jubail Chemical Industries Co, Saudi Arabia.
• Tamilnadu Petroproducts Limited, Chennai, India
Fertilizer
• Coromondel International Ltd., India
• Mangalore Chemicals & Fertilizers Ltd, Mangalore
• Madras Fertilizers Limited, Chennai, India
• Foskor Pty Ltd, South Africa
• Matix Fertilizers Ltd, India
• Paradeep Phosphate Limited, India
Others
• Omega Simulation Company, Japan
• Yokogawa, India, Bahrain, Singapore, Netherland
• SCIENSIM Sdn Bhd, Malaysia
• Technocrat Automation Solution Pvt Ltd.
• SVL Engineering Pvt Ltd, Chennai, India
• Sathyam Computer Services Ltd, Chennai, India
• Trident / RSI SIMCON, Inc, USA
• Fantoft Process Technologies / Kongsberg, Norway
• Technip, Chennai
• GIL Automation, Nigeria
Academics
• More than 25 colleges in India

 


IndiaSoft Technologies (P) Ltd., Prime Landmark, Office No.8, 3rd Floor, Sr. No. 63, Plot No. 44,
Guru Nanak Society,  Kondhwa Khurd, Pune 411 048
Ph. : 020 - 65002395/96, Fax. : 020 - 26850999, E-mail: mail@indiasoft.co.in,  www.indiasoft.co.in